Two Wheeler Technologies

An insight in to measures taken in India to lower the

emissions of 2-stroke two wheelers

Dr. M Subramanian
Senior Research Manager
Indian Oil Corporation Ltd.
Research and Development Centre
Faridabad, India

SAE – EC JRC Joint International Conference

(Particle) Emissions of 2-stroke Scooters
– science, problems, solutions & perspectives
Autodromo Nazionale Monza / Milano / Italy June 11th – 12th, 2009
OVERVIEW

Introduction
Two Wheeler Industry
Two Wheeler Technology
Two Wheeler Exhaust Emission Norms
Future Technologies
Two Wheeler Manufacturers
Conclusion

2
INDIAN TWO WHEELER INDUSTRY
yIndia, is the second largest producer of two-wheelers
in the world. In the last few years, the Indian two-
wheeler industry has seen spectacular growth. The
country stands next to China and Japan in terms of
production and sales respectively.

yMajority of Indians, especially the youngsters prefer

motorbikes rather than cars. Capturing a large share in
the two-wheeler industry, bikes and scooters cover a
major segment. Bikes are considered to be the favorite
among the youth generation

yLarge variety of two wheelers are available in the

market, known for their latest technology and enhanced
mileage. Indian bikes, scooters and mopeds represent
style and class for both men and women in India.
Growth of Two wheeler Industry

4
Sustaining of 2-Stroke Engine
¾ Two-stroke two-wheelers had higher emission
levels than the four-stroke engines. As a result of
tighter emissions norms, it was thought that the
two-stroke engine will die a natural death.
¾ Technological capabilities of the Indian automakers
with tremendous R&D work to put 2-stroke engines
and they are continuing with their two-stroke
models.
¾ BS-I Catalytic converters
¾ BS-II -Combination of bigger sized catalysts, dual
catalyst system and secondary air injection as
needed to reduce emissions
¾ BS-IV BACK TWO – STROKE ENGINE TECHNOLOGY
5
Scenario in 1990

ƒ Before 1990 – 2-stroke engines are lower fuel efficiency- higher pollution
ƒ Rapid growth in motor vehicle and other energy intensive activities has
caused air quality to deteriorate rapidly in Indian cities.
ƒ In Delhi, suspended particulate matter (PM) levels more than WHO limit
ƒ 2- stroke engines were widely used in both two-wheelers and three wheelers
recognized main contribution for more emissions and visible smoke
ƒ NGOs actively involved in controlling air pollution
ƒ Supreme court directives become legislation

6
Emission Regulations of Two-Wheelers

7
Emission control in Two-Strokes - Year : 1991

o Engine tuning
o Low dosage of lubricating oil for 2-stroke engine.
o The newly developed low dosage oil reduced 50 percent of lubricating oil
consumption.
o Engine technology developed to control precise requirement of
lubricating oil by introducing mechanically actuated Auto lube system.
o Over dosage was prevented by premixing of lubricating oil in the petrol
filling station itself.
o The above measures considerably reduced PM and HC emissions, and
visible smoke

8
Emission control in Two-Strokes - Year : 1996

‰ Re-designed ports ( increased No. of ports)

‰ Exhaust system improvements for effective scavenging and
reduced mixture short-circuiting
‰ Improved carburetion to produce leaner air–fuel mixtures
‰ Higher compression ratios
‰ Electronic ignition
‰ Combustion chamber and spark-plug location re-designed
‰ Piston re-design to minimise crevice volumes and friction
losses
‰ Intake and exhaust system designs (reed valves)
‰ Introduction of catalytic converters in 4 Metro
9 …
Emission control in Two-Strokes - Year: 2000

™ Engine optimization for increasing fuel efficiency

™ Unleaded gasoline introduced across the country
™ Intake, exhaust and combustion system optimization
™ Oxidation catalysts were additionally employed on both
two- and four-stroke engines
™ Stringent norms for new vehicles and retro fitment for in-
use vehicles

10
Indian Auto Policy 2002
The Government of India approved a comprehensive automotive policy in March 2002, the
main proposals of which are as under:
Foreign direct investment : Automatic approval is proposed to be granted to foreign
equity investment up to 100% for manufacture of automobiles and components.
Import tariff : Import tariffs are proposed to be fixed at a level such that they facilitate the
development of manufacturing capabilities as opposed to mere assembly.
Incentives for R&D : The weighted average tax deduction under the Income Tax Act,
1961 for automotive companies is proposed to be increased from current level of 125% (The
weighted average deduction for R&D was increased to 150% in the Union Budget 2004-05).
Further, the policy proposes to include vehicle manufacturers for a rebate on the applicable
excise duty for every 1% of the gross turnover of the company expended during the year on
R&D.
Environmental aspects : Adequate fiscal incentives are proposed to promote the use of
low-emission auto fuel technology (in line with the Auto Fuel Policy). The auto policy states
the Government's intent to align domestic policy with the international practice of imposing
higher road tax on old vehicles so as to discourage their use.

11
Emission control in Two-Strokes - Year: 2005

9 Transformation and innovation and adopt new technology

9 Fuel efficient vehicles
9 Improvements in Fuel quality :
9 Reduction of Fuel Sulphur <150 ppm
9 Reduction of benzene contents
9 Secondary air injection into catalytic converter
9 Improved Catalytic Converters
9 Durability / warranty for exhaust gas treatment devices
9 Alternative fuels ( ethanol in gasoline)
12
Few specific technologies used in the present
day two-wheelers in India

„ Digital Twin Spark Ignition

(DTSi)
„ Variable Timing (VT-i)
Fuel Economy
„ Electronic Fuel Injection
a major driving
„ 3- Valve Engines factor
„ Over Square Engines

13
Emission control in Two-Strokes - Year: 2010

o Fuel Sulphur < 50 ppm

o Several options for fuel injection system for two stroke
engines.
o The injection could be Direct or in the transfer port.
o Best results can be achieved by in-cylinder injection
which could be mechanical, pneumatic/compressed air
assisted, or electronically controlled.
o Use of gaseous fuels (LPG / CNG)
o Improved after treatment system

14
FUTURE TECHNOLOGIES
Future Technologies
2-Strokes
y Effective three-way catalytic converter
y Electronic Air Assisted Direct fuel injection with oxidation
catalytic converter.
y LPG , CNG
y CNG+H2

4-Strokes
y Port fuel Injection with 3-way catalyst converter
y Air assisted direct injection with oxidation / 3-way
catalyst converter
y Gaseous fuels technology (CNG, LPG). CNG+H2
y Safety systems
16
Future Technologies

Battery electric two wheelers may dominate the two

wheeler mobility beyond 2015
y Nickel metal hydride battery
y Lithium ion and Lithium polymer batteries
y Size, Weight, Vehicle range, Cost and Life are the
issues
y Hybrid electric technology

17
 Manufacturers of Electric Two-Wheelers
Scooters India
Hero Electric
BSA Motors
Luminous Power Technologies
TVS Motors
Ultra Motors
Indus Elec-Trans
Bajaj auto ltd
TVS – Scooty Teenz Electric

YoSmart electric scooter - Indus

Elec-Trans Ultra Motors Marathon
Hero Ultra Velociti
18 Electric Scooter electric scooter
Conclusions

y Two –wheeler industries are technology driven

y Well established R&Ds for taking any challenge and

integrated manufacturing system.

y Advanced manufacturing system for quality product

y Products are performance driven

y Future technology for near zero emission with

advanced engine technology and electric-power
2-wheeler

19
20
Two Wheelers – Comparative Characteristics

Moped Scooter Motorcycle

2-stroke, 4-
Stroke 2-stroke Mainly 4-stroke
stroke
Engine Capacity 100, 125, >
50, 60 90-150
(cc) 125
Ignition Kick/Electronic Kick/Electronic Kick/Electronic
Engine Power
2-3 6.5-9 7-8 and above
(bhp)
Weight (kg) 60-70 90-100 > 100

Fuel Efficiency
70-80 50-75 50-80+
(km per litre)

Load Carrying Low High Highest

21 Source: ICRA Sectoral Analysis

Evolution of 2- Stroke Technology
1945, Trading company by Bajaj Auto Limited,
1959, They obtained government approval to manufacture of Two
and Three-wheelers, under license from Piaggio of Italy (the
maker of the famous Vespa scooters)
1970 Bajaj Auto Limited developed own models
Until 1980s, Few manufacturers- catering for a modest,
predominantly domestic market, characterised by government
restrictions on production capacities, tariffs, and low levels of
competition.
1980 OEMs collaborate / joint venture with Japanese two wheeler
manufacturer for technology up-gradation
Four stroke engine technology introduced by JVC of Hero-
Honda a well engineered and fuel-efficient 100 cc four-
stroke motorcycle of Japanese design
2000 De-licensed -Industries established own R&D
Today more than 10 major manufacturer – 2-Stroke and 4-
stroke two wheeler
22
TWO WHEELER EXHAUST
EMISSION NORMS
Exhaust Emission Norms in India - Year : 1991

2010
Vehicle Pollutants 1991 1996 2000 2005*
**

CO 12 -30 4.5 2.0 1.5 1

Two-
wheelers
(gm/Km) HC + NOx 8-12 3.6 2.0 1.5 1

24
 Exhaust Emission Norms in India - - Year : 1996

Vehicle Pollutants 1991

1996 2000
BS-II
2005
BS-III
2010

Two-
CO 12 -30
4.5 2.0 1.5 1

wheelers
(gm/Km) HC + NOx 8-12
3.6 2.0 1.5 1

Emission standards have been made particularly stringent, and have been tightened.
Achieved with four-stroke motorcycles, due to the superior emission characteristics

25
India 2000 Norms

Vehicle Pollutants 1991 1996

2000 2005*
2010
**

Two-
CO 12 -30 4.5
2.0 1.5 1

wheelers
(gm/Km) HC + NOx 8-12 3.6
2.0 1.5 1

26
Exhaust Emission Norms

Vehicle Pollutants 1991 1996 2000 2005

2010

Two-
CO 12 -30 4.5 2.0 1.5
1
wheelers
(gm/Km) HC + NOx 8-12 3.6 2.0 1.5
1

27
 Bharat Stage – III

Vehicle Pollutants 1991 1996 2000 2005 2010

**

CO 12 -30 4.5 2.0 1.5 1

Two-
wheelers
(gm/Km) HC + NOx 8-12 3.6 2.0 1.5 1